Method of making loose-leaf binder case construction



I -'..S. SCHADE METHOD OF MAKING LOOSE-LEAF BINDER CASE CONSTRUCTIONS 2Sheets-Sheet 1 Original Filed Nov. 15. 1946 INVENTOR xkqm' d'mmurd'c/moz(7%; ,9L HTTORNEYS F. S. SCHADE Aug. 2, 1949.

METHOD OF. MAKING LOOSE-LEAF BINDER CASE QQNSTRUCTIONS "2 Sheets-Shet 2Original Filed Nov. 15, 1946 INVENTOR 7 5M, dmvzz demo:

BY W W ATTORNEYS Patented Aug. 2, 1949 METHOD OF MAKING LOOSE-LEAFBINDER CASE CONSTRUCTIONS Frank Stanley Schade, Holyoke, Mass., assignorto National Blank Book Company, Holyoke, Mass, a corporation ofMassachusetts Original application November 15, 1946, Serial Divided andthis application March 19, 1948, Serial No. 15,826

6 Claims. 1

This invention relates to improvements in the methods of laminatingsheet plastics, the new method being particularly useful in binder caseconstruction for books as its use results in an improved product madeefliciently and economically.

In the prior art, the nearest method to the present invention that isknown to me, is to be found in my Patent No. 2,390,125 issued December4, 1945. That patent shows how to make an economical book binder case ofuseful character by laminating plastic sheets of limp character togetherwith panel inserts for stiffening the covers and the back portion in aparticular way to give special advantages. Important features ofconstruction disclosed in that patent are retained in the constructionmade by the method of this invention. The important differences betweenthe two methods of laminating will become evident after the steps formaking efiiciently, a binder case of high quality, fine appearance, andlow cost are disclosed as an example of the present invention. A usefulproduct made by the method of the present invention is disclosed in mycopending application, Serial No. 709,956 filed November 15, 1946, ofwhich this application is a division. It is to be noted that while theexample chosen is a binder case for a loose leaf binder, the method oflaminating disclosed in the present invention is equally adapted formaking a binder case for a permanently bound book.

In the drawings:

Fig. 1 is a plan view of the binder case with rivets indicated forattaching a ring mechanism on the back portion, but without suchmechanism being shown;

Fig. 2 is a diagrammatic view showing the profile considered centrallyof the binder case of Fig. 1;

Fig. 3 is an enlarged section taken on line 3-3 of Fig. 1, broken awayin part for convenience of illustration;

Fig 4 is a perspective view of the elements which are combined to formthe binder of Fig. 1. The various parts are spaced from each other inorder to show them more clearly;

Fig. 5 is a small scale perspective view showing a modified form ofstifiener panel;

Fig. 6 is a perspective view of a tool used in assembling the parts ofFig. 4;

Fig. 7 is a, fragmentary plan view of a sheet containing a plurality ofbinder cases like the one indicated in Fig. 1, with the plurality inassembled but uncut form; and

Fig. 8 is a perspective view like Fig. 4 showing a modified form havingonly two sheets, one limp sheet and a stiffener panel sheet.

The new laminating method of this invention is particularly adapted tomaking a binder case as shown in plan and section in Figs. 1 and 3 ofthe drawings. They show a plan view of an opened binder case consistingof a back portion I, two hinged cover portions 2 and 3, and hingeportions b, all of laminated material. Rivets 4 have been shown on theback portion 1 for assembly of ring mechanism, not shown. Although thebinder case is particularly useful for loose leaf books and the drawingsshow such as an example, the binder case may easily be adapted forpermanently bound books.

By way of disclosing the new method, the feature of the improvedlaminated product in the examples of Figs. 1, 2 and 3 will now bedescribed. This example retains important advantages seen in theconstruction of said prior patent, i, e. Fig. 7 of that patent, and addsimprovements.

A main improvement is in the nature of the cover portions. Referring toFigs. 1 to 4, the two limp plastic sheets 5 and B, seen in Fig. 4, areto enclose stiffening panels H as in Fig. 3. They are welded together onbuffer margin a and on hinge bands b. The panels H of stiffening sheetI, however, are not welded to the material of limp sheets 5 and 6 asthese sheets enter into the form of Fig. 3 under the method of making tobe described. The portion of limp plastic material from sheet 5overlying each panel II and the corresponding portion of limp plasticmaterial from sheet 6 underlying each panel II in the assembly of Fig.3, are portions which are not fastened together or to the panel I l ineither cover 2 or cover 3 in the final binder case construction. Thelimp sheets 5 and 6 are fastened together, however, around substantiallythe whole margin of each panel II in bands a and b. The result is thatthe limp sheet plastic material on opposite sides of each panel H, canmove relatively to the stifiening panel H and to each other. Themovement will be permitted due to the limp character of the outersheets, aided by some elasticity of the material and in spite of thebinding margin seen in bands a and b. These marginal bands limit thedegree of relative movement in the cover areas where the stiffeningpanels are laminated. When these cover areas are handled by the usertheir outside limp sheets are given a limited creeping movement withrelation to the stiffening material of the panels. These same coverareas of the limp sheets also have enough looseness inside their edgemargins a and b to take a slightly wavy surface form when either coveris slightly lbent, particularly on the inside surface of the bend, Whenthe covers are laid out flat these same cover areas have a slightlybuilt up appearance, :i. e. a slight degree of pufiiness thatdistinguishes them from a flat hard looking surface. Together thesethings give a nature to the cover portions which closely simulates arich soft leather action .and appearance.

The significant improvement over my prior patent is strikingly apparentto the eye :and to the feeling of the binder "case, or o'thenslimilararticle made by the laminating method of this invention, in the hands ofthe user. inated binder case product f the example is indicated in theenlarged scale of Fig. 3 to show better the arrangement of elements. The,profile of Fig. 2 better shows the nature of the binder caseconstruction for its sheet form of covers 2 and 3, back'p'ortionI,'*h'inge'strips b, and peripheral bulier margin a, especially when theprofile of Fig. 2 is 'consideredwith the plan view of Fig. 1. Theimproved appearance seen in thisbinder case construction as compared tothe construction of said patent is much more remarkable when thetangible products instead of the drawings are compared. The prior"product and the improved productmay'be made o'fthe same limp sheetplastic material 'an'd'stiffening panels. By leaving the laminationsloose "in the manner described the binding case product is improved.

In the new laminating method, the product is also improved by theconstruction of the back panel element made "of the .parts'as indicatedin Figs. 3 and 4. The rivets 4 are'fasten'ed atone end to the stiffstrip 8 "for carrying them in the desired spacing. This strip islaminated in the back panel with 'stiiieningpa'nel I2 and 'the'backpanel portions in the "area *o'f'limp plastic sheets 5 and 6, asindicated in Fig. 4. This example'of back panel construction shows oneadapted for low cost steps in making of'the binder case constructionwith rivets builtfin to 'takethe loose leaf mechanism. The utility ofthis feature will be seen better whenthe'meth'od o'fmaking the productis described.

The method involves welding the two limp plastic sheets '5 and 6 alongmargins-wand bands 22, into a single limp'sheet'strip for margin buffera and into bands I) forthe hinges. A useful tool to do this is shownin'Fig. 6. 'Oneexample of the method will be disclosed "with "referenceto the use of this tool I3.

A preferred, but not a necessary, order 'of method steps is'as'follows': the'shan'ks of rivets are put throughholes IIl of thestifiener sheet I. This sheet is preferabl stamped out in the form ofFig, '4, for "convenien'ce'in handling its panel portions as a unit.Slots I are lone enough so that the "short "portions -of materialconnecting the three panels will be of no consequence in the action ofthe hinge "bands to be made. The rivet shanks aretlren-passed throughholes 9 of limpsheet'li. This assembly of carrying strip 8, rivets'lysheet "I and'sh'eet 5 is then laid over the tool "I3 of Fig. '6 withthe sheet 5 contacting the tool "ledges I6 and I! with the rivet shankspassinginto correspondingly spaced holes M of thetool. -'Sheet5,.shown.untrimmed in Fig. 4,.need only be large 'enoughto extend to or beyondthe perimeter of tool 13. "It can be trimmed to size later. On top ofsuch assembly on tool I3 is next laid limp sheetB. This should have anoverall area large enough to extend to The .lam- 1".

or beyond the periphery of tool I3. It will be noted that rivets 4 willhold the whole assembly, except sheet 6, from shifting or swiveling andthat sheet 6 being on top of the laminations is under observation and-'can"be'-'e'asily arranged in proper positionywhich is merely flat tocover the tool.

With all parts placed on tool I3, in flat and loosely laminated positionas stated, a flat plate electrode or an electrode shaped correspondingto tool T3 is pressed on top of the assembly positionedtontool I 3. Thetool I3 is also an electrode. The plan involves pressing narrow bands ofthe two limp sheets of plastic material, one band a for thebuffer-margin and two bands 12 for the hinge bandsapplying heat to theseband portions :to heat seal their two laminations over the limited areasof such bands. Such sealing is done by welding such areas into singlelimp sheet form over the band areas while leaving the rest of the areas"of laminations loose and unsealed at least in the-areas of thecoverpanels, and preferably including the area of the back panel, for the'efiect of the creeping action and the better appearance 'in the productasbefore stated.

The welding is preferably done by a high frequency current passedbetween the electrodes with the 'diel'ectriciplastic material pressedbetween them. The heat sealing could be done in other ways, as by 'a"heated iron corresponding to tool 13 pressing the material on saidtool, but the heatin'g'is preferably done by a high frequency currentpassed "between electrodes through the thermoplastic material pressedbetween them. This is .ac'cording to theway of dielectric heating.

Itshoul'd be noted that there are recesses of depth (I between theridges I6 and I! of tool I3. They avoid a Welding'heat on the materialabove the recesses while the welding is .done on the material abovetheridges. 'The recess I5 between ridges Il isproportionedffor holes I4to hold the rivet shanks :in an effective .manner while the sheetslaminated lie ilat across ridges I'I.

After iheat sealing, the binder case is neatly trimmed by cuttingisharply :around the outer edge of limp buffer margin a, to the edgeshown in Fig. 1 for example. .Instead of heat sealing binder cases011622.17 a time, many can be heat sealed at one time. The-tool I3.ofFig, 6 may be duplicated in onehelectrode .pla e of large area tocorrespond with the band areas a and b for the buffer :and hinge bandsas indicatedin Fig. '7. Then the parts of many binders can be pinned bytheir :rivetparts '4 to :the .holes provided, as before stated inrelation to Fig 6. Finally a large enough sheet :6 to .cover .the areaof all the subassemblies can be laid 'on, the second electrode can bepressed down and current passed through all the band areas 'a and bto'simultaneously heat :these vportionsby dielectric heating. Fig. 7indicates the multiple sheet resulting and of course the electrodeswould 'be made to correspond. When the binding case construction of sucha s'heetis trimmed as c'an be 'done by a multiple cuttingdie-foperation,=each case construction will be'like the single one'o'fFig.1. The construction is particularly'adapted to this multiple orsimul- -taneous finishing 'of "many-products at one time.

Referring now to modifications: Fig. 5 shows a's'tifienin'g'sheet 7'like sheet 11 of Fig. 4 except that "hinge creases I8 instead of slotslike II "are provided. "The use of sheet "I' is generally like that.ofsheet 'L-the limp sheets .5 .and 6 cooperating with creases I8instead of with slots II, to

make flexible hinge lines in the final assembly of this modification.

Fig. 8 indicates an assembly like that of Fig. 4 with the differencethat stifiening sheet 22 like that of Fig. 5 is used and limp plasticsheet 5 is omitted. The sheet 22 is made of plastic material or amaterial that can be heat sealed with a margin of sheet 6. In thismodification the peripheral bufier margin of sheet 6 area is heat sealedto a narrow peripheral margin of sheet 22 so that the loose character oflamination exists between most of the cover areas and the stifieningsheet 22. The latter is preferably heat sealed along lines just outsidethe hinge lines in this modification as would be useful in any case ofusing the stiffening sheet form of Fig. 5. In the final result theoutside surface of the covers will be the same as the preferredconstruction of Fig. 1, but the inside surface of the covers in themodification of Fig. 8 will have a harder appearance and feel to thetouch. The modification will give a lower cost construction and stillretain the improved appearance and feel to the touch on the outside ofthe covers where it is more important to have than on the insidesurface. The tool it of Fig. 6 is adapted to serve all modifications. Asan electrode it is adapted for heat sealing along its flat like, narrowband ridges l6 and H, the rest of the area being recessed enough toavoid heat sealing. As above stated the type of Fig. 1 construction isthe preferred one but it will be seen that various modifications may bemade while retaining an important part of the invention shown in theFig. 1 construction.

When a loose leaf binder mechanism is attached to the binder caseconstruction by rivets t, it will itself stiffen the back portion and noback panel stifiening portion will be necessary. But it is a convenienceto handle all three panels in sheet 7 as a unit. In case a permanentlybound book instead of a loose leaf binder is wanted, the shanks ofrivets t or equivalent parts may be shortened or be short enough instructure to be more studs for positioning the parts as stated incarrying out the method steps. The binder case construction can then beapplied and fastened to permanently bound fillers in any well known way.The construction of Fig. l is, however, particularly useful for makinghigh quality binding case construction for loose leaf binders.

Considering the quality of the preferred form of the Fig. l binder casemade by the new and improved method of laminating, it has already beencompared to that of said prior art Patent No. 2,390,125 of 1945. Itshould be compared also to the type of leather laminated binder caseconstruction such as may be made by stitching sheets together and handtooling the edges. Suppose the outside cover sheet were limp leather,the inside cover sheet were: also of limp leather, and cover stiileningpanels were laminated between them. The fastening would commonly be doneby stitching down the buffer band and hand tooling the buffer edge togive a line appearance. The resulting fine, rich leather binding wouldbe comparatively expensive. Its fine appearance, however, is approachedto a very close degree by this invention, keeping in mind that the limpsheet plastic material both as to surface decoration, to movement underfinger touch, and to book wearing quality can be made substantially theequivalent of fine leather. Taking this into account, together with thefact of saving in cost of material, stitching, and hand tooling forleather binding work, the comparison with the sheet plastic work underthis invention is very much in favor of the new product.

The new method may be considered as an improvement over that of saidprior patent in that the new one results in a product which brings theart into much closer identity with the high quality of fine leatherbindings than the one of said patent while retaining importantadvantages of the improvement seen in said patent.

Having disclosed the method invention, the claims are:

I claim:

1. The method of making loose leaf binder case constructions whichconsists in mounting two rivets at corresponding ends on a spacer strip,mounting on the strip a single stiffening sheet divided by spaced slotscorresponding to hinge strips for said stiifening sheet to furnish twocover and back portion stiffening panels, mounting in the same way alimp sheet of plastic material over the stifiening strip on the spacerstrip by passing the rivets through holes correspondingly spaced in thelimp sheet, said stiffening sheet being of less area than the limp sheetto leave an extended peripheral margin of the latter, insorting therivets in. correspondingly spaced holes of a heat sealing tool so that asub-assembly is mounted on the tool with the said stiiiening sheetfacing outwardly then covering said subassembly with a second limp sheetof plastic material having an overall area to cover the said stiffeningsheet and the extended margin of the first limp sheet, the elements ofthe binder case being then laminated loosely, heat sealing the limpsheets together between the spaced slots of said stiffening sheet andall around a narrow band area adjacent the outside edge of saidstiffening sheet but otherwise leaving the laminated sheets generally inunsealed condition with respect to their contacting surfaces.

2. The method of making loose leaf binder case constructions whichconsists in mounting two rivets at corresponding ends on a spacer strip,mounting the strip on a single stiffening sheet divided by spaced slotscorresponding to hinge bands for said stiffening sheet to furnish twocover and back portion stiffening panels, mounting this unit in the sameWay on a limp sheet of plastic material by passin. the rivets throughholes clorrespondiingly spaced in the limp sheet, said limp sheet havingan area greater than the stiffening sheet to leave an extendedperipheral margin, inserting the rivets in correspondingly spaced holesof a heat sealing tool so that a sub-assembly is mounted on the toolwith the said stifiening sheet facing outwardly, and placing additionalstiffening sheets, and spacer strips with rivets mounted therein inspaced relation on the limp sheet by inserting the rivets in othercorrespondingly spaced holes of the tool, then covering all suchstiifening sheets and spacer strips with a second limp sheet of plasticmaterial having an overall area approximately equal to that of the firstlimp sheet, th elements of a plurality of binder cases being thuslaminated loosely, simultaneously heat sealing the limp sheets togetherbetween the spaced slots of all said stifiening sheets and all around anarrow hand area adjacent the outside edge of each of said stiffeningsheets but otherwise leaving the laminated sheets generally in unsealedcondition with respect to their contacting surfaces, and finally cuttingout of the laminated limp sheets many binding case constructions.

3. The method of making a binder case consavages struction whichconsists'iniproviding two pins'on a spacer strip, positioning a sheet ofstiffening material having stiffening panels corresponding to twocovers-and a back portion divided by flexible hinge lines in thestiffening sheet; positioning in the same manner a limp sheet of plasticmaterial on the spacer-stripwith said pins holding through correspondingholes of the limp sheet, said assembly having the limp sheet extendingbeyond the edges of the stiffening sheet, laying said assembly on flatlike ridges of a heat sealing tool which ridges outline a peripheralmargin and hinge lines for the binder case, laying a second limpsheet'of plastic materialiover said assembly to cover all of it and thenfastening the loosely laminated material by heat sealing on aperipheralmargin of both sheets of plastic material to enclose thestiffening sheet and heat sealing along the hinge lines of saidstiffening sheet by pressure and heat applied in the areas correspondingto the, ridges of said heat sealing tool.

4. The method, of making a binder case which consists in grooving asheet of stiifening material adapted for heat-"sealing, the groovingbeing along hinge lines to divide the sheet into cover and back panelportions, pinning said sheet in predetermined position on the face of aheat sealing tool having ridges. defining lines and a peripheral marginfor, the binder case, said sheet being pinned to lie on. the tool andleave the ridges defining the peripheral margin substantially uncoveredby the sheet, then laying a limp sheet of plastic, material. of largeenough area to cover said. stiifening sheet all overv and beyond it tocover the last named ridges of the heating tool, then heat sealing; thesheets together on a line adjacent and around the periphery of thestiifener sheet and along the hinge lines so as to leave the laminationsloose at least in the cover areas between the hinge lines and saidperipheral heat sealing line.

5. The method of making loose leaf binder case constructions whichconsists in laying a limp sheet of an area equal to many binding caseson the plate of a heat sealing tool of corresponding area, providingholes in the limp sheet corresponding to holes in the sealing tool witha pair of such holes spaced along each axis corresponding to thelongitudinalaxis of the back portion area in areas over the face of thetool on which many binder case constructions are to be made, assemblingmany spacer strips with rivets mounted in each adjacent opposite end andspaced to correspond with the spacing of a pair of holes along saidaxis, making many stifiening sheets each having cover and back panelportions provided with slots through the sheet at the sides of the backpanel, and with holes through the back panel spaced correspondingly withthe rivets of the spacer strips, pinning each stiffener panel to thelimp sheet and to the tool in separated areas on the face of the tool bypassing the rivets through corresponding holes so that the limp sheet onthe tool has mounted on it said many stiffening sheets in separatedareas with peripheral margins of the limp sheet around each asiiisembly, covering: the; many assemblies on said limp sheet with a secondlimp sheet of plastic material, heati sealingby welding the two limpsheetsxdirectly -together under, pressure and heat applied along the,peripheral bands of the sheets around the margin, of each, said assemblyand through the: slots along the sides of each back panel portion, of;the: stifiener sheets and leaving such stiffener. sheets unwelded tothelimp sheets and in loosely laminated form in their pocketed positionsbetween theswelded bands and finally separating the-many binder caseconstructions by cutting them apart within the welded area of the; said.peripheral, bands connecting adjacent binder case constructions asmadeon the tool.

6. Thev'method of making loose leaf binder case constructions: whichconsists in laying a limp sheet of plastic material over the face of aheat sealing tool having spaced ridges thereon and spaced holes thereinso that other spaced holes provided in the limp sheet register with theholes in the tool, mounting on the limp sheet a single stiifeningcsheethaving matchingv holes to register. with the other holes, such sheetbeing divided by slots spaced to correspond with the ridges on the toolforsaid stiffening sheet to fur nish two cover andbackportion stifieningpanels, said'stiffenin-g sheet being of less area than the limp sheetto-leave,v an extended peripheral margin of thelatter whenplacedthereon, mounting two pinsat corresponding ends on a spacer strip andpassing; them not only through the holes of the'stifiener; sheet butalso into the correspondingly spacedholes of the tool with spacer stripfiat against the stiffener sheet and the latter against the limpsheet.so that a sub-assembly is mounted on the limp sheet on said tool,assembling other spacer strips with rivets and pinning other stiffenersheets to the limp sheet on the tool by the rivets in like manner toform a plurality of said sub-assemblies, then covering all suchsub-assemblies of stiffener sheets and spacer strips with a second limpsheet of plastic material spread over.- the. first limp sheet, theelements of a plurality of binder. cases being, thus laminated loosely,simultaneously heat sealing the limpsheets together between the spacedslots of all said stiffening sheets-and all around a narrow band area,adjacent the outside edge of each of said stiifening. sheets butotherwise leaving the laminated sheetslgenerally in unsealed conditionwith respect to their contacting surfaces and finally cutting outof thelaminated limp sheets the many binding case constructions.

FRANK STANLEY SCHADE.

REFERENCES CITED The following referencesrare of record in the file ofthis'pat'ent:

UNITED STATES PATENTS Number Name Date 559,727 LEnfant May 5, 18952,024,881 Schade Dec. 1'7, 1935 2,177,879 Schade Oct. 31, 1939 2,390,125Schade Dec. 4, 194-5

